Inside StopFlex Carbon Ceramic Brake Disc Manufacturing

At StopFlex, our carbon-ceramic discs harness the true power of long carbon fiber reinforcement, not the shorter chopped strands typical of mass-market discs. We begin by weaving continuous, high-strength fibers into a 3D preform that mirrors the final disc structure—enhancing toughness and heat management far beyond what small fragmented fibers can achieve. After shaping, the preform undergoes vacuum silicon infiltration at 1700 °C, converting it into a durable C/SiC composite. This advanced process results in discs that resist cracking up to ~1800 °C, absorb heat more efficiently, and maintain structural integrity under punishing conditions—delivering supercar-grade braking for discerning drivers.

Step 1
Toray T800 carbon fiber cloth and yarn, the lightweight raw materials for a STOPFLEX carbon ceramic disc.
Carbon Fiber Weave

Fiber Frame

We tightly weave aerospace-grade T800 carbon fibers into a lattice (like high-tech carpet!), creating a lightweight disc "skeleton". Every thread is precision-aligned to handle insane braking forces.

Step 2
Layers of carbon fiber cloth stacked into a dense black brick, the preform for a STOPFLEX carbon ceramic disc.
Resin & Reinforcement

Layered Armor

Each fiber layer gets coated in a secret sauce: carbon powder + silicon carbide + resin, dried, then stacked with reinforcement mesh—15 layers thick (think bulletproof lasagna!). This 30mm sandwich forms the disc’s core.

Step 3
A square carbon fiber brick being precision CNC-machined into the circular shape of a semi-finished brake disc.
Pressure Baking

Density Locked

We press-and-bake the stack at 180°C & 25 MPa (that’s 3,600 PSI!) for 2 hours. This fuses everything into a rock-solid "green body" (density: 1.6 g/cm³)—lighter than aluminum, stronger than steel.

Step 4
A brake disc inside a 1,550°C vacuum furnace during the silicon carbide infusion stage of the manufacturing process.
Silicon Fusion

Born in a Vacuum

The disc meets molten silicon at 1,550°C (sun-surface heat!) in a vacuum chamber. Silicon soaks into every pore, reacting to form silicon carbide ceramic—nature’s armor. Result? A disc that shrugs off 1,500°C track heat.

Step 5
A CNC machine using a diamond tool to polish the surface of a STOPFLEX carbon ceramic disc for a balanced finish.
Mill & Polish

Race-Ready Refinement

After cooling, we machine ventilation channels and diamond‑grind the surface to a mirror finish (≤0.02mm). The result? A disc with perfect cooling, precise fit, and minimal dust—ready for high‑performance use.

Step 6
A STOPFLEX carbon ceramic disc glowing red hot during a 900°C high-temperature performance test on a dynamometer.
Quality Control

Rigorous Brake Testing

We batch‑test every StopFlex carbon‑ceramic disc through brutal bench cycles: from 200 km/h down to zero, over and over, non‑stop for a full hour. During this ordeal, temperatures hover around 900 °C, and the disc must hold a rock‑steady friction coefficient from start to finish. That’s how we guarantee your brakes stay sharp—whether shredding laps or stopping on the street.